Packaging Assemblies And Methods

ABSTRACT

A packaging assembly including an outer sleeve, a tray, and an insert arranged within the tray. The tray may be arranged within and slidably engage with the outer sleeve. The tray may include a base, a first and second lateral sidewall, and a first and second longitudinal sidewall. The first and second lateral sidewalls each may include a first, a second, and a third portion. The first, second, and third portions are folded to form the first and second lateral sidewalls. The first and second longitudinal sidewalls each may include a first and a second flap. The first and the second flap may be arranged on opposite ends of the first and second longitudinal sidewalls. The first flaps may be arranged between the first and third portions of the first lateral sidewall, and the second flaps may be arranged between the first and third portions of the second lateral sidewall.

BACKGROUND Field

The present specification generally relates to packaging assemblies andmethods and, more specifically, to packaging assemblies formed from flatmaterial and folded to create the packaging assembly components andmethods for assembling the same.

Technical Background

Packaging assemblies, such as cardboard boxes, can be used forcost-effective packaging. However cardboard boxes are limited to thesize which the boxes are manufactured to, and do not include additionalinserts which can be used for specific applications. As such, additionalpackaging material, such as foam, may be required to keep objects withina cardboard box from moving during transit. Additionally, cardboardboxes only have a single opening, which requires tape or some other formof securement means to keep lid of the cardboard box secured shut.

Accordingly, a need exists for alternative packaging assemblies whichcan be assembled from flat material, while also having interchangeableinserts for specific applications.

SUMMARY

According to a first aspect, a packaging assembly including an outersleeve, a tray, and an insert. The outer sleeve may include an aperture.The tray may be arranged within the aperture and slidably engage withthe outer sleeve. The tray may include a base, a first lateral sidewall,a second lateral sidewall, a first longitudinal sidewall, and a secondlongitudinal sidewall. The first lateral sidewall and a second lateralsidewall each may include a first portion, a second portion, and a thirdportion. The first, second, and third portions are folded to form thefirst and second lateral sidewalls. The first longitudinal sidewall anda second longitudinal sidewall may each include a first flap and asecond flap. The first flap and the second flap may be arranged onopposite ends of the first and second longitudinal sidewalls. The firstflaps may be arranged between the first portion and third portion of thefirst lateral sidewall, and the second flaps may be arranged between thefirst portion and third portion of the second lateral sidewall. Theinsert may be arranged within the tray.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the first portions are parallel to the thirdportion when in a folded configuration to form the first and secondlateral sidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the second portions are parallel to the basewhen in a folded configuration to form the first and second lateralsidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, further comprising tabs arranged on the third portionsof the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the tabs of the third portions engage withapertures formed in the base of the tray to secure the first, second,and third portions in a folded configuration, forming the first andsecond lateral sidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the flaps of the first and second longitudinalsidewalls are perpendicular to the first and second longitudinalsidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the flaps of the first and second longitudinalsidewalls are encapsulated by the base and first, second, and thirdportions of the first and second lateral sidewalls when in a foldedconfiguration to form the first and second longitudinal sidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the first, second, and third portions of thefirst and second lateral sidewalls and the first and second longitudinalsidewalls fold along indentations formed within the tray.

Another aspect includes a packaging assembly according to any of theprevious aspects, further comprising at least one divider integrallyarranged on the insert.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the at least one divider is formed integrallywithin the insert by folding a portion of the insert along a pluralityof indentations formed within the insert.

Another aspect includes a packaging assembly according to any of theprevious aspects, the divider is substantially flush with the first andsecond longitudinal sidewalls and the first and second lateralsidewalls.

Another aspect includes a packaging assembly according to any of theprevious aspects, where at least one goods receiving channel is formedbetween the tray and the insert.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the insert secures within the tray through afriction force which the insert exerts on the tray.

Another aspect includes a packaging assembly according to any of theprevious aspects, where the insert engages a channel formed between afirst and second lateral sidewalls and the base of the tray.

According to a second aspect, a method of forming a packaging assemblymay include forming an outer sleeve, a tray, and an insert. A first flatmaterial may be folded along a plurality of indentations formed withinthe first flat material to form the outer sleeve. The outer sleeve mayinclude an aperture formed therein. The tray may be formed by creating afirst longitudinal sidewall, a second longitudinal sidewall, a firstlateral sidewall, and a second lateral sidewall. A second flat materialmay be folded along a first longitudinal indentation formed within thesecond flat material to form the first longitudinal sidewall. A firstflap and a second flap of the first longitudinal sidewall may be foldedperpendicular to the first longitudinal sidewall. The second flatmaterial may be folded along a second longitudinal indentation formedwithin the second flat material to form the second longitudinalsidewall. A first flap and a second flap of the second longitudinalsidewall may be folded perpendicular to the second longitudinalsidewall. The second flat material may be folded along a first lateralindentation formed within the second flat material to form the firstlateral sidewall. The second flat material may be folded along a secondlateral indentation formed within the second flat material to form thesecond lateral sidewall. The first longitudinal sidewall, secondlongitudinal sidewall, first lateral sidewall, and second lateralsidewall form a base of the tray. A third flat material may be foldedalong a first indentation and a second indentation formed within thethird flat material to form the insert including at least one divider.The insert may be arranged within the tray, and the tray and insert maybe arranged within the aperture of the outer sleeve, where the trayslidably engages with the outer sleeve.

Another aspect includes a method according to any of the previousaspects, further comprising folding the second flat material along athird lateral indentation and a fourth lateral indentation formed withinthe second flat material to form a first portion, a second portion, anda third portion of the first lateral sidewall.

Another aspect includes a method according to any of the previousaspects, further comprising folding the second flat material along afifth lateral indentation and a sixth lateral indentation formed withinthe second flat material to form a first portion, a second portion, anda third portion of the second lateral sidewall.

Another aspect includes a method according to any of the previousaspects, where the first portions of the first and second lateralsidewalls are parallel to the third portions of the first and secondlateral sidewalls when in a folded configuration to form the first andsecond lateral sidewalls.

Another aspect includes a method according to any of the previousaspects, where the second portions of the first and second lateralsidewalls are parallel to the base when in a folded configuration toform the first and second lateral sidewalls.

Another aspect includes a method according to any of the previousaspects, where the base and first, second, and third portions of thefirst and second lateral sidewalls encapsulate the first and secondflaps of the first and second longitudinal sidewalls.

Another aspect includes a method according to any of the previousaspects, further comprising arranging a first tab arranged on the thirdportion of the first lateral sidewall within a first aperture arrangedwithin the base of the tray, and arranging a second tab arranged on thethird portion of the second lateral sidewall within a second aperturearranged within the base of the tray.

According to a third aspect, a method of packaging baked goods using apackaging assembly is provided. The method includes forming an outersleeve comprising a top, a bottom and sides that extend between the topand the bottom. The outer sleeve has an aperture that extends betweenopposite ends of the sleeve. A tray is formed that includes a frontwall, a rear wall, side walls that extend between the front wall and therear wall and a bottom that extends between the front wall, the rearwall and the side walls. The tray is sized to be slidably receivedwithin the aperture of the outer sleeve. An insert including a base andmultiple dividers that extend upwardly from the base is formed to formchannels that are separated from one another. The insert sized to bereceived within the tray such that the base covers the bottom of thetray within areas between the dividers. The insert is placed within thetray. At least one of the channels is filled with baked goods that aresized to be received within the aperture of the sleeve. The baked goodrest on the base of the insert. The tray and baked goods are slid withinthe aperture of the sleeve from an open configuration to a closedconfiguration.

Another aspect includes a method according to any of the previousaspects, wherein the insert is formed by folding a flat cardboardmaterial into the multiple dividers.

Additional features and advantages of the embodiments described hereinwill be set forth in the detailed description which follows, and in partwill be readily apparent to those skilled in the art from thatdescription or recognized by practicing the embodiments describedherein, including the detailed description which follows, the claims, aswell as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description describe various embodiments and areintended to provide an overview or framework for understanding thenature and character of the claimed subject matter. The accompanyingdrawings are included to provide a further understanding of the variousembodiments, and are incorporated into and constitute a part of thisspecification. The drawings illustrate the various embodiments describedherein, and together with the description serve to explain theprinciples and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side perspective view of a packaging assembly, according toone or more embodiments shown or described herein;

FIG. 1B is a side perspective view of the packaging assembly of FIG. 1A,according to one or more embodiments shown or described herein;

FIG. 2A is a side perspective view of an outer sleeve, according to oneor more embodiments shown or described herein;

FIG. 2B is a top view of the unfolded outer sleeve of FIG. 2A, accordingto one or more embodiments shown or described herein;

FIG. 2C is a side perspective view of the outer sleeve of FIG. 2A in aflat configuration, according to one or more embodiments shown ordescribed herein;

FIG. 3A is a side perspective view of a tray, according to one or moreembodiments shown or described herein;

FIG. 3B is a top view of the unfolded tray of FIG. 3A, according to oneor more embodiments shown or described herein;

FIG. 4A is a side perspective view of an insert, according to one ormore embodiments shown or described herein;

FIG. 4B is a top view of the unfolded insert of FIG. 4A, according toone or more embodiments shown or described herein;

FIG. 5A is a side perspective view of an insert, according to one ormore embodiments shown or described herein;

FIG. 5B is a top view of the unfolded insert of FIG. 5A, according toone or more embodiments shown or described herein;

FIG. 6 is a partial side perspective view of a tray and insert,according to one or more embodiments shown or described herein;

FIG. 7 is a side perspective view of the packaging assembly containinggoods, according to one or more embodiments shown or described herein;and

FIG. 8 is a flowchart depicting a method of forming a packagingassembly, according to one or more embodiments shown or describedherein.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of packagingassemblies and methods of forming the same, examples of which areillustrated in the accompanying drawings. Whenever possible, the samereference numerals will be used throughout the drawings to refer to thesame or like parts.

As used herein, the term “lateral direction” refers to theforward-rearward direction (i.e., in the +/−Z-direction of the depictedcoordinate axes). The term “longitudinal direction” refers to thecross-direction (i.e., in the +/− vehicle X-direction of the depictedcoordinate axes), and is transverse to the lateral direction. The term“vertical direction” refers to the upward-downward direction (i.e., inthe +/− vehicle Y-direction of the depicted coordinate axes). As usedherein, “upper” and “above” are defined as the positive Y direction ofthe coordinate axis shown in the drawings. “Lower” and “below” aredefined as the negative Y direction of the coordinate axis shown in thedrawings.

Embodiments of a packaging assembly may include an outer sleeve, a tray,and an insert. The outer sleeve, tray, and insert may all be formed fromflat material and then folded along indentation or perforations formedin the flat material in order to form the outer sleeve, tray, andinsert. The outer sleeve may include an aperture that passes completelythrough the outer sleeve so the tray can slidably engage with the outersleeve and be removed from the outer sleeve in either direction, or theaperture may be arranged in a single side of the outer sleeve to onlyallow access to a single side of the outer sleeve. The tray may includea base, a first lateral sidewall, a second lateral sidewall, a firstlongitudinal sidewall, and a second longitudinal sidewall. The firstlongitudinal sidewall may include a first flap and a second flaparranged on opposite ends of the first longitudinal sidewall. The secondlongitudinal sidewall may include a first flap and a second flaparranged on opposite ends of the second longitudinal sidewall. The flapsof the first and second longitudinal sidewalls may be foldedperpendicular to the first and second longitudinal sidewalls. The insertmay be arranged within the tray while the tray is arranged within theouter sleeve. The insert may include a plurality of dividers eitherarranged along the lateral or longitudinal direction. Variousembodiments of packaging assemblies and methods for assembling the samewill be described herein with specific reference to the appendeddrawings.

Embodiments according to the present disclosure include components thatallow a packaging assembly to be assembled from flat material which isfolded along indentations and perforations in order to create thepackaging assembly components. Additionally, the removable insert allowsfor the same sized tray to be used for different applications, dependingwhat item(s) need to be arranged within the tray for packaging. Forexample, the removable insert can include additional indentations ineither the longitudinal or lateral direction in order to create moredividers and goods receiving channels within the removable insert.

As used herein, the term “flat material” refers to any rigid orsemi-rigid substrates of material including, but not limited tocardboard, plastic, or the like. Flat materials are materials that havea resistance to bending under the force of gravity and remain flat whenheld in a cantilevered fashion. Such flat material can be stamped and/orperforated to provide fold lines along which the flat material may befolded to form a desired structure.

Referring now to FIGS. 1A and 1B, an embodiment of a packaging assembly100 is schematically depicted. The packaging assembly 100 generallyincludes an outer sleeve 102, a tray 104, and an insert 120. The insert120 may be arranged within the tray 104, and the tray 104 may beslidably engaged with the outer sleeve 102 so as to be able to slide inand out of the outer sleeve 102 in the longitudinal direction(+/−X-axis). The outer sleeve 102, tray 104, and insert 120 may bemanufactured from pieces of flat material (e.g., substrates made fromcardboard, plastic, or similar materials) which are stamped and/orperforated along predetermined lines and then folded along suchpredetermined lines to form the outer sleeve 102, tray 104, and insert120.

Referring now to FIGS. 2A and 2B, an embodiment of the outer sleeve 102is schematically depicted. The outer sleeve 102 generally includes afirst portion 102A (a top), a second portion 102B (a side), a thirdportion 102C (a side), a fourth portion 102D (a bottom), a fifth portion102E (a bottom), indentations 103, overlapping portion 106, overlappingportion 108. When assembled, as illustrated in FIG. 2A, the outer sleeve102 forms an aperture 110 for receiving the tray 104 and insert 120.When unfolded, the outer sleeve 102 may be a flat rectangular piece ofmaterial. Such flat orientation may provide a reduced profile, which mayallow for compact storage. In order to create the outer sleeve 102, theouter sleeve 102 may be folded along the indentations 103 at 90-degreeangles, forming the outer sleeve 102. The indentations 103 may becreated within the outer sleeve 102 through a stamping and/or scoringprocess.

Referring still to the embodiment depicted in FIGS. 2A and 2B, in afolded configuration, the first portion 102A, the fourth portion 102D,and the fifth portion 102E may extend in the X-Z plane. Additionally,the second portion 102B and the third portion 102C may extend in the X-Yplane. The fourth portion 102D and the fifth portion 102E each mayinclude overlapping portions 106, 108, respectively. Once each portion120A-120E is folded at a 90-degree angle along indentations 103, theoverlapping portions 106, 108 will overlap one another in the verticaldirection (+/−Y-axis). The overlapping portion 106, 108 can be securedto one another by an adhesive, mechanical means, or the like, in orderto keep the outer sleeve 102 in the folded configuration. Additionally,in some embodiments and as depicted in FIG. 2C, the outer sleeve 102 maybe pre-adhered and flattened along the indentations 103, where theaperture 110 is created by unflattening the outer sleeve 102 and spacingthe first portion 102A and fourth and fifth portions 102D, 102Evertically apart from one another. With the outer sleeve 102 in thefolded configuration, the aperture 110 is formed between the firstportion 102A, the second portion 102B, the third portion 102C, thefourth portion 102D, and the fifth portion 102E. The aperture 110extends through the entire outer sleeve 102 so that the tray 104 may beslid out of the outer sleeve 102 in either direction longitudinally(+/−X-axis). In some embodiments, one end of the outer sleeve 102 may beenclosed so that the aperture 110 does not pass through the entire outersleeve 102.

Referring now to FIGS. 3A and 3B, an embodiment of a tray 104 isschematically depicted. The tray 104 generally includes a firstlongitudinal sidewall 112 (a side), a second longitudinal sidewall 114(a side), a first lateral sidewall 116 (a front), a second lateralsidewall 118 (a rear), and a base 119 (a bottom). The first and secondlongitudinal sidewalls 112, 114 may be connected to the base 119 at thefirst and second longitudinal indentations 140A, 140B, which allow thefirst and second longitudinal sidewalls 112, 114 to be folded at90-degree angles relative to the base 119 in order to form the first andsecond longitudinal sidewalls 112, 114. The first longitudinal sidewall112, the second longitudinal sidewall 114, the first lateral sidewall116, the second lateral sidewall 118, and the base 119 may form aninsert space 132, where the insert 120 may be arranged within the tray104. Additionally, the first and second longitudinal sidewalls 112, 114may each include first and second flaps 134A, 134B, which may bearranged on opposite ends of each of the first and second longitudinalsidewall 112, 114. The first and second flaps 134A, 134B may be foldedat a 90-degree angle along indentations 143, making the first and secondflaps 134A, 134B perpendicular to the first and second longitudinalsidewalls 112, 114 in a folded configuration.

Referring still to the embodiment depicted in FIGS. 3A and 3B, each ofthe first and second lateral sidewalls 116, 118 may include a firstportion 116A, 118A, a second portion 116B, 118B, and a third portion116C, 118C. The first portions 116A, 118A may be folded along a firstlateral indentation 141A and a second lateral indentation 141B at a90-degree angle with respect to the base 119 in a folded configuration.Additionally, the second portions 116B, 118B may be folded along a thirdlateral indentation 141C and a fourth lateral indentation 141D at a90-degree angle with respect to the first portions 116A, 118A. Evenfurther, the third portions 116C, 118C may be folded along a fifthlateral indentation 141E and a sixth lateral indentation 141F at a90-degree angle with respect to the second portions 116B, 118B. Thecombination of folds along the lateral indentations 141A-141F betweenthe first portions 116A, 118A, the second portions 116B, 118B, the thirdportions 116C, 118C, and the base 119 arranges the first portions 116A,118A parallel to the third portions 116C, 118C, and arranges the secondportions 116B, 118B parallel with the base 119, respectively. A firstchannel 135 may form in-between the first portion 116A, the secondportion 116B, the third portion 116C, and the base 119 in a foldedconfiguration. Additionally, second channel 137 may form in-between thefirst portion 118A, the second portion 118B, the third portion 118C, andthe base 119 in a folded configuration.

The first and second flaps 134A, 134B of the first and secondlongitudinal sidewalls 112, 114 may be disconnected from the firstportions 116A, 118A via cuts 139, allowing the first and second flaps134A, 134B to move and be folded independently of the first portions116A, 118A of the first and second lateral sidewalls 116, 118. Whenfolded, the first flaps 134A of the first longitudinal sidewall 112 andthe second longitudinal sidewall 114 may arranged within the firstchannel 135 formed by the first portion 116A and the third portion 116Cof the first lateral sidewall 116, and the second flaps 134B of thefirst longitudinal sidewall 112 and the second longitudinal sidewall 114may be arranged within the second channel 137 formed by the firstportion 118A and the third portion 118C of the second lateral sidewall118 in a folded configuration. By arranging the first and second flaps134A, 134B within the first and second lateral sidewalls 116, 118, thefirst and second longitudinal sidewalls 112, 114 are secured in a foldedconfiguration. In the folded configuration, the first and second flaps134A, 134B may be encapsulated by the base 119, first portions 116A,118A, second portions 116B, 118B, and third portions 116C, 118C of thefirst and second lateral sidewalls 116, 118 when folded to form thefirst and second longitudinal sidewalls 112, 114.

Referring still to the embodiment depicted in FIGS. 3A and 3B, the base119 may further include apertures 138A, 138B arranged therein.Additionally, the third portions 116C, 118C may include tabs 136A, 136Barranged on the ends of the third portions 116C, 118C and configured tobe inserted into the apertures 138A, 138B, respectively. For example,when the first portion 118A, the second portion 118B, the third portion118C, and the base 119 are in a folded configuration, the tabs 136A,136B are aligned in the vertical direction (+/−Y-axis) and may beinserted into the apertures 138 a, 138B within the base 119. Theinteraction between the tabs 136A, 136B and the apertures 138A, 138Bsecure the first portions 116A, 118A, the second portions 116B, 118B,and the third portions 116C, 118C in a folded configuration to form thefirst and second lateral sidewalls 116, 118.

Referring now to FIGS. 4A and 4B, an embodiment of an insert 120 isschematically depicted. The insert 120 generally includes a divider 122,a base portion 124, and a base portion 126. Together, the base portions124 and 126 may form a floor of the tray 104 and may cover at leastabout 90 percent of an interior surface area of the base 119. Thedivider 122 may include a vertical portion 122A, a horizontal portion122B, and a vertical portion 122C. The vertical portion 122A may befolded at a 90-degree angle with respect to the base portion 126 inorder to arranged the vertical portion 122A in the vertical direction(+/−Y-axis). Additionally, the vertical portion 122C may be folded at a90-degree angle with respect to the base portion 124 in order toarranged the vertical portion 122C in the vertical direction(+/−Y-axis). The vertical portions 122A, 122C may be folded at a90-degree angle along indentations 130A, 130B with respect to thehorizontal portion 122B. The combination of folds along perforations128A, 128B and indentations 130A, 130B between the vertical portion122A, horizontal portion 122B, vertical portion 122C, the base portion124, and the base portion 126 creates the divider 122 integrally withinthe insert 120. Once the divider 122 is formed within the insert 120,the insert 120 may be correctly sized to be arranged within the insertspace 132 of the tray 104 (FIG. 1B). The divider 122, when folded mayhave a height (in the +/−Y direction of the depicted coordinate axes),which when inserted into the tray 104 is substantially flush with a topof the sidewalls 112, 114, 116, and 118 when the insert 120 is arrangedwithin the tray 104.

Referring now to FIGS. 5A and 5B, an embodiment of an insert 120′ isschematically depicted. In some embodiments, the insert 120′ may replacethe insert 120 within the tray 104 if more dividers are desired for aspecific application (e.g., holding various rows of baked goods).Additionally, even though the insert 120′ is depicted with only threedividers, it should be appreciated that any number of dividers may beformed within the insert 120′ (e.g., 2 or more, 3 or more, 4 or more, 5or more, etc.). The insert 120′ generally includes a base portion 154, abase portion 156, a base portion 158, a base portion 160, a divider 162,a divider 164, and a divider 166. Together, the base portions 154, 156and 158 may cover at least about 90 percent of an interior surface areaof the base 119. The divider 162 may include a vertical portion 162A, ahorizontal portion 162B, and a vertical portion 162C. The verticalportion 162A may be folded at a 90-degree angle with respect to the baseportion 154 along perforation 168A in order to arrange the verticalportion 162A in the vertical direction (+/−Y-axis). Additionally, thevertical portion 162C may be folded at a 90-degree angle with respect tothe base portion 156 along perforation 168B in order to arrange thevertical portion 162C in the vertical direction (+/−Y-axis). Thevertical portions 162A, 162C may be folded at a 90-degree angle alongindentations 170A, 170B with respect to the horizontal portion 162B. Thecombination of folds along perforations 168A, 168B and indentations170A, 170B between the vertical portion 162A, horizontal portion 162B,vertical portion 162C, the base portion 154, and the base portion 156creates the divider 162 integrally within the insert 120′.

Referring still to the embodiment depicted in FIGS. 5A and 5B, thedivider 164 may include a vertical portion 164A, a horizontal portion164B, and a vertical portion 164C. The vertical portion 164A may befolded at a 90-degree angle with respect to the base portion 156 alongperforation 168C in order to arrange the vertical portion 164A in thevertical direction (+/−Y-axis). Additionally, the vertical portion 164Cmay be folded at a 90-degree angle with respect to the base portion 158along perforation 168D in order to arrange the vertical portion 164C inthe vertical direction (+/−Y-axis). The vertical portions 164A, 164C maybe folded at a 90-degree angle along indentations 170C, 170D withrespect to the horizontal portion 164B. The combination of folds alongperforations 168C, 168D and indentations 170C, 170D between the verticalportion 164A, horizontal portion 164B, vertical portion 164C, the baseportion 156, and the base portion 158 creates the divider 164 integrallywithin the insert 120′.

Referring still to the embodiment depicted in FIGS. 5A and 5B, thedivider 166 may include a vertical portion 166A, a horizontal portion166B, and a vertical portion 166C. The vertical portion 166A may befolded at a 90-degree angle with respect to the base portion 158 alongperforation 168E in order to arrange the vertical portion 166A in thevertical direction (+/−Y-axis). Additionally, the vertical portion 166Cmay be folded at a 90-degree angle with respect to the base portion 160along perforation 168F in order to arrange the vertical portion 166C inthe vertical direction (+/−Y-axis). The vertical portions 166A, 166C maybe folded at a 90-degree angle along indentations 170E, 170F withrespect to the horizontal portion 166B. The combination of folds alongperforations 168E, 168F and indentations 170E, 170F between the verticalportion 166A, horizontal portion 166B, vertical portion 166C, the baseportion 158, and the base portion 160 creates the divider 166 integrallywithin the insert 120′. Once the dividers 162, 164, and 166 are formedwithin the insert 120′, the insert 120′ may be correctly sized to bearranged within the insert space 132 of the tray 104 (as depicted inFIG. 3A). It is important to note that the insert 120 may be arranged sothat the divider 122 extends in the longitudinal direction (+/−X-axis).Additionally, the insert 120′ may be arranged so that the dividers 162,164, and 166 extend in the lateral direction (+/−Z-axis). Also, thedividers 162, 164, and 166 may have the a vertical height (+/−Y-axis) sothat the horizontal portions 162B, 164B, and 166B may be flush with thesidewalls 112, 114, 116, and 118 when the insert 120′ is arranged withinthe tray 104.

Referring now to FIG. 6, an embodiment of a tray 104 and insert 120′ isschematically depicted. The second flap 134B of the first longitudinalsidewall 112 is not illustrated for simplicity. As the first portion118A, second portion 118B, and the third portion 118C are folded tocreate the second lateral sidewall 118, a small gap 171 may form betweenthe base 119 of the tray 104 and the second lateral sidewall 118. As theinsert 120′ is arranged within the insert space 132 of the tray 104, aportion 172 of the base portion 160 may be arranged within the gapformed between the base 119 and the second lateral sidewall 118. Theportion 172 may secure the insert 120′ within the tray 104.Additionally, if a gap is not formed within the tray 104, the insert120′ may engage the first and second lateral sidewalls 116, 118 so as tobe held in place within the tray 104 due to a friction or pressurebetween the first and second lateral sidewalls 116, 118 and the insert120′. For example, the insert 120′ may exert a friction force againstthe first and second lateral sidewalls 116, 118. The force exerted bythe insert 120′ as the insert 120′ attempts to unfold within the tray104 may secure the insert 120′ within the tray 104.

Referring now to FIG. 7, the packaging assembly 100 filled with goods 50is depicted. In some embodiments, the combination of the tray 104 andthe insert 120 may form goods receiving channels 131 when the insert 120is arranged within the tray 104. The goods receiving channels 131 may beused to store goods 50 within the packaging assembly 100, such as bakedgoods (e.g., cookies, cakes, pastries, etc.), and prevent the goods 50from shifting or becoming damaged during transportation. The insert 120may include a plurality of goods receiving channels 131, and may bedirectly related to the number of dividers 122 arranged within theinsert 120. Additionally, it should be appreciated that the goodsreceiving channels 131 may be various forms, such as rectangles,squares, or the like without departing from the scope of thisdisclosure.

Referring now to FIG. 8, a flow chart depicting a method 200 forassembling the packaging assembly 100 (as illustrated in FIGS. 1-6) isdepicted. It is noted that while a number of steps are shown in aspecific order, embodiments may include a greater or fewer number ofsteps in varying orders without departing from the scope of the presentdisclosure. To begin, at step 202 the method 200 may include folding afirst flat material 10 for folding into the outer sleeve 102 along aplurality of indentations 103 formed within the first flat material 10to form the outer sleeve 102. For example, and with reference to FIGS.2A and 2B, the outer sleeve 102 may be made from a single piece of flatmaterial 10, where the indentations 103 are formed in the outer sleeve102 in order to fold the outer sleeve 102 from a flat material 10 into afolded configuration. In some embodiments, the first flat material 10may be pre-adhered and flattened prior to assembly of the packagingassembly 100, where the flat material 10 is folded into a standingposition such as illustrated in FIG. 2C in order to form the outersleeve 102.

Referring again to FIG. 8, step 204 may include folding a second flatmaterial 20 for folding into the tray 104 along a first longitudinalindentation 140A formed within the second flat material 20 to form afirst longitudinal sidewall 112. For example, and as described above,the tray 104 may be formed from a single piece of flat material 20,where the first longitudinal sidewall 112 is folded at a 90-degree anglewith respect to the base 119 to form the first longitudinal sidewall112. Step 206 may include folding a first flap 134A and a second flap134B of the first longitudinal sidewall 112 perpendicular to the firstlongitudinal sidewall 112. For example, and with reference to FIGS. 3Aand 3B, the first and second flaps 134A, 134B may be folded at a90-degree angle along indentations 143.

Referring again to FIG. 8, step 208 may include folding the second flatmaterial 20 for folding into the tray 104 along a second longitudinalindentation 140B formed within the second flat material 20 to form asecond longitudinal sidewall 114. For example, and as described above,the tray 104 may be formed from a single piece of flat material 20,where the second longitudinal sidewall 114 is folded at a 90-degreeangle with respect to the base 119 to form the second longitudinalsidewall 114. Step 210 may include folding a first flap 134A and asecond flap 134B of the second longitudinal sidewall 114 perpendicularto the second longitudinal sidewall 114. For example, and with referenceto FIGS. 3A and 3B, the first and second flaps 134A, 134B may be foldedat a 90-degree angle along indentations 143.

Referring again to FIG. 8, step 212 may include folding the second flatmaterial 20 for folding into the tray 104 along a first lateralindentation 141A formed within the second flat material 20 to form afirst lateral sidewall 116. For example, and with reference to FIGS. 3Aand 3B, the first lateral sidewall 116 is formed from first portion116A, second portion 116B, and third portion 116C, all of which arefolded at a 90-degree angle with respect to one another to form thefirst lateral sidewall 116. Step 214 may include folding the second flatmaterial 20 along a second lateral indentation 141B formed within thesecond flat material 20 to form a second lateral sidewall 118. Forexample, and with reference to FIGS. 3A and 3B, the second lateralsidewall 118 is formed from first portion 118A, second portion 118B, andthird portion 118C, all of which are folded at a 90-degree angle withrespect to one another to form the second lateral sidewall 118.

Referring again to FIG. 8, step 216 may include folding a third flatmaterial 30 for folding into the insert 120 along a first indentation130A and a second indentation 130B formed within the third flat material30 to form an insert 120 including at least one divider 122. Forexample, and with reference to FIGS. 4A-5B, the insert 120 may include asingle or a plurality of dividers 122, where the dividers 122 are formedby folding the insert 120 at a 90-degree angle along the perforations128A, 128B or the indentations 130A, 130B. It should be noted that theinsert 120 can include a plurality of dividers arranged in either thelongitudinal or longitude direction, for example, insert 120′ depictedin FIG. 5A. Step 218 may include arranging the insert 120 within thetray 104. For example, and as described above, once the insert 120 is ina folded configuration, the insert 120 can be arranged within the insertspace 132 of the tray 104.

Referring again to FIG. 8, step 220 may include arranging the tray 104and insert 120 within the aperture 110 of the outer sleeve 102, wherethe tray 104 slidably engages with the outer sleeve 102. For example,and with reference to FIG. 1B, the tray 104 is slidably engaged withinthe aperture 110 of the outer sleeve 102, allowing the tray 104 to beremoved from the outer sleeve 102 in either longitudinal direction(+/−X-axis).

The method may further include arranging baked goods (e.g., cookies,cakes, etc.) within the goods receiving channels of the tray. Rows ofthe baked good may be separated by the dividers. The method may furtherinclude shipping the packaging assembly to a recipient.

It should now be understood that embodiments described herein aredirected to a packaging assembly and methods of assembly of thepackaging assembly. The packaging assembly may include an outer sleeve,a tray, and an insert. The outer sleeve may include an aperture thatpasses completely through the outer sleeve so the tray can slidablyengage with the outer sleeve and be removed from the outer sleeve ineither direction. The tray may include a base, lateral sidewalls, andlongitudinal sidewalls. The lateral sidewalls and longitudinal sidewallsare folded with respect to the base in order to form the tray. Theinsert may be arranged within the tray while the tray is arranged withinthe outer sleeve. The insert may include a plurality of dividers eitherarranged in the lateral or longitudinal direction.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the embodiments describedherein without departing from the spirit and scope of the claimedsubject matter. Thus it is intended that the specification cover themodifications and variations of the various embodiments described hereinprovided such modification and variations come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. A packaging assembly, comprising: an outersleeve, wherein the outer sleeve comprises an at least one aperture; atray arranged within the aperture, wherein the tray slidably engageswith the outer sleeve, the tray comprising: a base; a first lateralsidewall and a second lateral sidewall arranged opposite from oneanother and coupled to the base, each of the first lateral sidewall andthe second lateral sidewall comprising: a first portion; a secondportion; and a third portion, wherein the first, second, and thirdportions are folded to form the first and second lateral sidewalls; afirst longitudinal sidewall and a second longitudinal sidewall arrangedopposite from one another and coupled to the base, each of the firstlongitudinal sidewall and the second longitudinal sidewall comprising: afirst flap; and a second flap, wherein the first flap and the secondflap are arranged on opposite ends of the first and second longitudinalsidewalls, and the first flaps are arranged between the first portionand third portion of the first lateral sidewall, and the second flapsare arranged between the first portion and third portion of the secondlateral sidewall; and an insert arranged within the tray.
 2. Thepackaging assembly of claim 1, wherein the first portions of the firstand second lateral side walls are parallel to the third portions of thefirst and second lateral side walls when the tray is in a foldedconfiguration.
 3. The packaging assembly of claim 2, wherein the secondportions of the first and second lateral sidewalls are parallel to thebase when the tray is in the folded configuration.
 4. The packagingassembly of claim 3, further comprising tabs extending from the thirdportions of the first and second lateral sidewalls.
 5. The packagingassembly of claim 4, wherein the tabs of the third portions engage withapertures formed in the base of the tray to secure the first, second,and third portions in the folded configuration, forming the first andsecond lateral sidewalls.
 6. The packaging assembly of claim 5, whereinthe flaps of the first and second longitudinal sidewalls areperpendicular to the first and second longitudinal sidewalls when in thefolded configuration.
 7. The packaging assembly of claim 6, wherein theflaps of the first and second longitudinal sidewalls are encapsulated bythe base and first, second, and third portions of the first and secondlateral sidewalls when in the folded configuration to form the first andsecond longitudinal sidewalls.
 8. The packaging assembly of claim 1,further comprising at least one divider integrally arranged on theinsert.
 9. The packaging assembly of claim 8, wherein the at least onedivider is formed integrally within the insert by folding a portion ofthe insert along a plurality of indentations formed within the insert.10. The packaging assembly of claim 9, wherein the at least one dividersubstantially flush with the first and second lateral sidewalls and thefirst and second longitudinal sidewalls.
 11. The packaging assembly ofclaim 9, wherein at least one goods receiving channel is formed betweenthe tray and the insert.
 12. The packaging assembly of claim 10, whereinthe insert secures within the tray through a friction force which theinsert exerts on the tray.
 13. The packaging assembly of claim 10,wherein the insert engages a channel formed between a first and secondlateral sidewalls and the base of the tray.
 14. A method of packagingbaked goods using a packaging assembly, the method comprising: formingan outer sleeve comprising a top, a bottom and sides that extend betweenthe top and the bottom, the outer sleeve having an aperture that extendsbetween opposite ends of the sleeve; forming a tray comprising a frontwall, a rear wall, side walls that extend between the front wall and therear wall and a bottom that extends between the front wall, the rearwall and the side walls, wherein the tray is sized to be slidablyreceived within the aperture of the outer sleeve; forming an insertcomprising a base and multiple dividers that extend upwardly from thebase to form channels that are separated from one another, the insertsized to be received within the tray such that the base covers thebottom of the tray within areas between the dividers; placing the insertwithin the tray; filling at least one of the channels with baked goodsthat are sized to be received within the aperture of the sleeve, thebaked good resting on the base of the insert; and sliding the tray andbaked goods within the aperture of the sleeve from an open configurationto a closed configuration.
 15. The method of claim 14, wherein theinsert is formed by folding a flat cardboard material into the multipledividers.
 16. A method of forming a packaging assembly, comprising:folding a first flat material along a plurality of indentations formedwithin the first flat material to form an outer sleeve, the outer sleevecomprising an aperture; forming a tray, comprising: folding a secondflat material along a first longitudinal indentation formed within thesecond flat material to form a first longitudinal sidewall; folding afirst flap and a second flap of the first longitudinal sidewallperpendicular to the first longitudinal sidewall; folding the secondflat material along a second longitudinal indentation formed within thesecond flat material to form a second longitudinal sidewall; folding afirst flap and a second flap of the second longitudinal sidewallperpendicular to the second longitudinal sidewall; folding the secondflat material along a first lateral indentation formed within the secondflat material to form a first lateral sidewall; and folding the secondflat material along a second lateral indentation formed within thesecond flat material to form a second lateral sidewall, wherein thefirst lateral sidewall, the second lateral sidewall, the firstlongitudinal sidewall, and the second longitudinal sidewall form a baseof the tray; folding a third flat material along a first indentation anda second indentation formed within the third flat material to form aninsert, the insert comprising at least one divider; arranging the insertwithin the tray; and arranging the tray and insert within the apertureof the outer sleeve, wherein the tray slidably engages with the outersleeve.
 17. The method of forming a packaging assembly of claim 16,further comprising folding the second flat material along a thirdlateral indentation and a fourth lateral indentation formed within thesecond flat material to form a first portion, a second portion, and athird portion of the first lateral sidewall.
 18. The method of forming apackaging assembly of claim 17, further comprising folding the secondflat material along a fifth lateral indentation and a sixth lateralindentation formed within the second flat material to form a firstportion, a second portion, and a third portion of the second lateralsidewall.
 19. The method of forming a packaging assembly of claim 18,wherein the first portions of the first and second lateral sidewalls areparallel to the third portions of the first and second lateral sidewallswhen in a folded configuration to form the first and second lateralsidewalls.
 20. The method of forming a packaging assembly of claim 19,wherein the second portions of the first and second lateral sidewallsare parallel to the base when folded to form the first and secondlateral sidewalls.